WO2007006358A1

WO2007006358A1 - Knee brace

Info

Publication number: WO2007006358A1
Application number: PCT/EP2006/004365
Authority: WO
Inventors: Jean-Patrick Jaccard
Original assignee: Sports & Supports Limited
Priority date: 2005-07-12
Filing date: 2006-05-10
Publication date: 2007-01-18
Also published as: ITMI20051313A1; WO2007006358B1

Abstract

A knee brace (100) comprises: an upper element (101) designed to be disposed to encircle the user's thigh above the knee, a lower element (102) designed to be disposed to encircle the user's leg below the knee, and at least one articulated system (6) which connects the upper element (101) to the lower element (102). Each upper and lower element (101, 102) comprises a first portion (5) and a second portion (5') with substantially the same shape as the first portion (5). Each portion (5, 5') comprises a solid band (50) and a plurality of laces (52) which protrude from one end of the solid band (50), the laces (52) of the first portion (5) being crossed with the laces (52) of the second portion (5') and the ends of the laces (52) being closed by means of closing means (8), so as to constrain to each other the two portions (5, 5') of the respective brace element.

Description

KNEE BRACE

DESCRIPTION

The present invention refers to the field of articles for health and orthopaedic use for rehabilitation and prevention of injury and in particular to a brace for knee joints or knee support designed to prevent strains and thus loading of the collateral ligaments of the knee.

Various types of knee braces or supports are currently known to the market, which take the form of a tube open at each end to be worn on the patient's lower limb. The tube contains two rods articulated in correspondence with the sides of the knee, known as the condyles. These braces have the drawback of not allowing a precise positioning of the rods to correspond with the condyles of the knee.

To overcome these drawbacks at least in part, braces are also known which have two tubular elements that can be opened at the front or at the back to be positioned on the thigh and on the leg. These tubular elements are connected to each other by means of an articulated system of rods that are laterally stiff but longitudinally articulated, so as to form two hinges.

Said articulated rods offer a good support against lateral stress, though maintaining a free longitudinal flexion and extension movement of the leg. The tubular elements are worn on the limb so that the axes of the hinges are disposed to correspond with the sides of the knee.

In this type of brace it is difficult to find a perfect alignment of the axis of the rods with the axis of rotation of the knee because of the production of these braces in standard sizes.

In fact it must be considered that some patients have great differences in the circumference of the proximal part of the leg (below the knee) and of the distal region of the thigh (above the knee). These great differences in circumference cause difficulties for the patient when choosing the size.

For example, a patient whose size is between large and extra-large for the distal region of the thigh and only medium for the proximal part of the leg will not be able to have his requirements met. Therefore, he will have to choose one of the sizes, large or medium, for both the distal and proximal parts, or have a brace made to measure, at a considerably higher cost than standard, off-the-shelf braces.

Obviously if the user does not succeed in finding the sizes to suit the shape of his limb, the centres of rotation of the rods of the brace will not be perfectly aligned with the axis of rotation of the knee, therefore the brace will not perform well and will present various functional defects.

Object of the present invention is to overcome the drawbacks of the prior art by providing a knee brace that is versatile and can be adapted to different lower limb shapes, offering the possibility of maintaining the lateral rods in the correct position though varying the circumference in the two regions, distal and proximal, independently of each other.

Another object of the present invention is to provide such a knee brace that is easy for the user to wear and ensures a perfect alignment of the centres of rotation of the rods with the axis of rotation of the knee. Another object of the present invention is to provide such a brace that is ambidextrous, that can be adapted so as to be worn either on the right limb or on the left limb. Yet another object of the invention is to provide such a brace that is cheap and simple to produce.

These objects are achieved according to the invention with the characteristics listed in appended independent claim 1. Advantageous embodiments of the invention are apparent from the dependent claims.

The knee brace according to the invention comprises:

- an upper element designed to be disposed to encircle the user's thigh above the knee,

- a lower element designed to be disposed to encircle the user's leg below the knee, and - at least one articulated system which joins said upper element to said lower element, to relieve the load on the collateral ligaments of the knee during flexion and extension movements of the leg.

The peculiar characteristic of the invention is represented by the fact that said upper and lower elements each comprise a first portion coupled to a second portion with substantially the same shape as the first portion. Each portion comprises a solid band and a plurality of laces, which protrude from one end of the solid band. The laces of the first portion are crossed with the laces of the second portion and the ends of said laces are closed by means of closing means, so as to constrain to each other the two portions of the respective element of the brace.

This system allows the two elements of the brace to be tightened by pulling the laces, so as to adapt them to the shape of the patient's lower limb. In this manner the centres of rotation of the articulated elements can be perfectly aligned with the axis of rotation of the knee, allowing the brace to function well.

Further characteristics of the invention will be made clearer by the detailed description that follows, referring to purely exemplifying and therefore non-limiting embodiment thereof, illustrated in the appended drawings, in which: Figure 1 is a partially broken off cross sectional view showing a multilayer sheet used for production of the knee brace according to the invention;

Figure 2 is a plan view showing a first portion of the knee brace according to the invention, taken from the side destined to face outwards;

Figure 2A is a plan view illustrating a second complementary portion designed to couple with the first portion of Figure 2;

Figure 3 is a plan view illustrating the brace according to the invention, with an articulated stabilizing system shown exploded;

Figure 3 A is a view like Figure 3, illustrating the transformation of a brace for the right limb into a brace for the left limb; Figures 4 and 5 are two perspective views illustrating two stages in assembly of a stabilizing rod of the articulated system;

Figures 6 to 10 are perspective views illustrating five sequences for fitting of a brace according to the invention to a patient's leg;

Figures 11 and 12 are two perspective views taken from different angles, illustrating the brace according to the invention fitted on the patient's leg;

Figures 13, 14 and 15 are three views like Figure 11, illustrating the brace according to the invention, in which the hinge of the rods is illustrated in a centred, in a forward and in a rearward position with respect to the condyles of the knee.

The knee brace or support according to the invention, denoted as a whole with reference numeral 100 and illustrated as a whole in Figure 3, is described with reference to the figures. The brace 100 comprises:

- an upper element 101 designed to be disposed to encircle the user's thigh above the knee,

- a lower element 102, substantially similar to the upper element 101, designed to be disposed to encircle the user's leg below the knee, and

- an articulated system 6, which joins the upper element 101 to the lower element 102 to stabilize flexion and extension movements of the knee.

Realization of the upper element 101 and of the lower element 102 starts from a flat multilayer sheet 1, as illustrated in Figure 1. The multilayer sheet 1 comprises:

- a bottom layer 2 destined to go towards the user's body,

- a middle layer of padding 3, and

- a top layer 4 destined to face outwards.

The bottom layer 2, being in contact with the skin, must be made of an anallergic, breathable material.

The middle layer 3 must be made of a cushioning, breathable material like an open-cell plastic foam material, for example, such as polyurethane (PU).

The upper layer 4 must have an upper surface suitable for Velcro-type coupling.

Therefore, the upper surface of the top layer 4 has a plurality of loops 40 able to couple, in an anchoring relationship, with a plurality of matching hooks of a Velcro-type fixing element, as will be described below.

For this purpose the top layer 4 can be made of nylon material, suitably treated, so as to obtain a top surface with a plurality of loops 40.

The bottom layer 2 can have portions with a plurality of hooks 20 able to couple with the loops 40 of the top layer 4.

The multilayer sheet 1 is preferably obtained by flame bonding. That is to say, the bottom layer 2 and the middle layer 3 are fed from two respective rolls. The middle layer 3 is made to pass near a flame which heats it on the side facing towards the bottom layer 2 to allow bonding thereof. Then, the two layers 2 and 3 are made to pass through a calender, which carries out bonding. The outer side of the middle layer 3 is subsequently flame heated and bonded by means of a calender with the top layer 4 fed from a roll.

The middle layer 3 made of PU allows good adherence with the bottom layer 2 and with the top layer 4, through flame bonding. Flame bonding is an example of the types of bonding between materials that can be performed; alternatively there are other methods such as spread or sprayed glues, hot glues, etc.

The multilayer sheet 1 , substantially rectangular in shape, is fed to a blanking machine. The multilayer sheet 1 is then compressed between two die halves which perform blanking along a pre-established outline, so as to obtain a first portion of brace 5, as shown in Figure 2.

The portion of brace 5 comprises a solid band 50, substantially rectangular in shape, with a rounded end 51. Near the end 51 of the band 50, a gripping portion 58 is provided, suitable to be gripped by the user.

A plurality of laces 52 shaped like rectangular strips protrude from the distal end with respect to the rounded end 51 of the band 50. The laces 52 are of the same length and width and are disposed equidistant from each other so as to define a plurality of spaces 53 of such a width as to be able to receive the laces 52 of another portion of brace. To be exact, five laces 52 are provided on the portion of brace 5.

A reinforcing strip 54 disposed crosswise with respect to the laces 52 is sewn on the top layer of the band 50. The reinforcing strip 54 forms a pocket 55 able to receive a rod or an insert of metal or of stiff plastic 60 (Figure 3), shaped like a flattened plate, forming part of the articulated stabilizer system 6, as will be described hereunder.

A leaf spring or clip 57 shaped like a small plate is hinged on the reinforcing strip 54 by means of a hinge 56 with a transverse axis with respect to the laces 52. The clip 57, when it is closed, passes through the whole reinforcing strip 54, so as to give rise to a narrowing of the pocket 55.

The first portion 5 is able to couple with a second complementary portion 5', as illustrated in Figure 2A, in which like parts to those already described are indicated with the same reference numerals and are not described. The second portion 5' differs from the first portion 5, in that it has six laces 52 and thus five spaces to accommodate the five laces 52 of the first portion 5.

As shown in Figure 3, the laces 52 of the first portion 5 are inserted into the spaces 53 of the second portion 5' and vice versa. Next, the ends of the laces 52 of each portion (5, 5') are fixed, by sewing, to the respective closing strips 8.

Each closing strip 8 comprises a bottom surface provided with hooks 20 able to engage, in a Velcro-type coupling relationship, with loops 40 present on the top surface of the solid band 50. The top surface of the closing strips 8 also has loops 40 for Velcro-type coupling.

hi this manner, the two portions of brace (5, 5') are constrained to each other, by crossing of the laces 52 and cannot come apart from each other precisely because the ends of the laces 52 are fixed to the closing strip 8. Both the upper brace element 101 destined to encircle the femoral part above the knee and the lower brace element 102 destined to encircle the tibia below the knee are obtained with this system. The two brace elements 101 and 102 are substantially the same.

In each brace element 101 e 102, the laces 52 of the two portions (5, 5') are alongside each other in the rear part forming a continuity of material when the respective brace element is open and is in the spread position, that is to say the two bands 50 of the two portions of brace (5, 5') are spaced apart from each other by a distance covered by the laces 52 arranged side by side.

Clearly, when the respective brace element is worn and tightened by pulling on the laces 52, the two bands 50 of the two portions (5, 5') come closer to each other and their distance is shortened.

The two elements of the brace (101, 101') are constrained to each other by means of two articulated stabilizing systems 6. Each articulated system 6 comprises two rods 60 hinged to a hinge 61, in a manner that is per se known and therefore is not illustrated. Beneath the hinge 61 there is disposed a cushioning pad 62 destined to come into contact with the lateral part of the user's knee.

In each rod 60 there is a rectangular slot or notch 63 designed to be engaged by the clip 57 of the respective portions of brace (5, 5'). As shown in Figure 4, the rod 60 is inserted into the pocket 55 defined by the reinforcing strip 54 on one portion 5' of brace, in the direction of the arrow F, when the clip 57 is open, that is to say substantially at right angles to the plane of the strip 54 on the band 50.

Then, as shown in Figure 5, the user manually pushes the clip 57, which rotates around the hinge 56, in the direction of the arrow F2. The clip is thus disposed tangent to the strip 54 giving rise to a narrowing of the pocket 55 and engages the slot 63 of the rod 60, locking it in position inside the pocket 55.

The rods 60 are suitably pre-shaped and have a central transitional portion 60' more or less inclined with respect to the proximal and distal portions of the hinge 61, so as to follow the anatomy of the knee perfectly.

Therefore, with reference to Figure 3 A there are provided an articulated lateral device 6a provided with a pair of rods 60 with a less inclined transitional portion 60' and a medial articulated device 6b provided with a pair of rods 60 with a more inclined transitional portion 60'.

Thanks to the clip device 57 disposed in the strip 54 of each pocket 55, the lateral rods 6a and the medial rods 6b are reversible. In fact it is sufficient to exchange the position of the lateral rods 6a with the medial rods 6b and to rotate them 180° to allow the right brace to be converted into a left brace and vice versa.

The operation of fitting the brace 100 on the user is described with reference to Figures 6 to 10.

As shown in Figure 6, the user disposes the upper element 101 of the brace around his thigh, above the knee, with the bottom layer 2 facing towards his body and the portion in which the laces 52 are side by side disposed rearward. Then, the user closes the upper element 101 of the brace to encircle his thigh, anchoring the hooks 20 provided on the bottom layer 2 of the band of the second portion 5' on the loops 40 provided on the top layer 4 of the band of the first portion 5 of the brace. During this first stage it is sufficient to make the anchoring portion 58 of the band 5 adhere to the surface 40 of the corresponding band 5', without applying traction forces. Then, as shown in Figure 7, the user performs the same operation for the lower element 102 of the brace, closing it to encircle the leg below the knee.

Once the two elements 101 and 102 of the brace have been closed in a ring and the hinges 61 of the stabilizing rods 6 are disposed coaxially with the axis of rotation of the knee, the tightening stage is performed, as shown in Figure 8. The user grips the closing strips 8 and tightens the laces 52 of the upper element. Then, as shown in Figure 9, the bottom surface 20 of the closing strips 8 is anchored on the top surface 50 of the bands 50 of the upper element 101.

As shown in Figure 10, the same tightening operation is carried out to tighten the lower element 102 of the brace.

In Figures 11 and 12 the brace 100 is shown fitted on the lower limb of the user, in which the upper element 101 and lower element 102 are tightened and the hinges 61 of the articulated system 6 are disposed coaxially with the axis of rotation of the user's knee.

Figures 13, 14 e 15 show the brace according to the invention, in which the hinge 61 of the rods 60 is illustrated respectively in the centred, in the forward and in the rearward position with respect to the condyles of the knee. Such a possibility of shifting the position of the hinge 61 of the rods 60 makes it possible to adapt the brace 100 to the various shapes of the patient's limb.

Numerous changes and modifications of detail within the reach of a person skilled in the art can be made to the present embodiment of the invention without departing from the scope of the invention as set forth in the appended claims.

Claims

1. A knee brace (100) comprising:

- an upper element (101) designed to be disposed to encircle the user's thigh above the knee,

- a lower element (102) designed to be disposed to encircle the user's leg below the knee, and

- at least one articulated system (6) which connects said upper element (101) to said lower element (102), to relieve the load on the collateral ligaments of the knee during flexion and extension movements of the leg, characterized in that each of said upper and lower elements (101, 102) comprises a first portion (5) and a second portion (5') with substantially the same shape as the first portion (5), each portion (5, 5') comprising a solid band (50) and a plurality of laces (52) which protrude from one end of said solid band (50), the laces (52) of the first portion (5) being crossed with the laces (52) of the second portion (5') and the ends of said laces (52) being closed by means of closing means (8), so as to constrain said two portions (5, 5') of the respective brace element to each other.

2. A brace according to claim 1, characterized in that it comprises two articulated systems (6), each articulated system comprising two stiff rods (60) hinged in a hinge (61) destined to be disposed to correspond with the condyles, so that the axis of the hinge is aligned with the axis of rotation of the knee.

3. A brace according to claim 2, characterized in that on said solid band (50) of each portion there is fixed a reinforcing strip (54) which defines a pocket (55) designed to accommodate said stiff rod (60) of the articulated system (6).

4. A brace according to claim 3, characterized in that on said reinforcing strip (54) of the solid band (50) of each portion there is hinged a leaf spring or clip (57) designed to give rise to a narrowing of the pocket (55) and to engage in a slot (63) in the stiff rod of the articulated system to lock it in position inside said pocket (55).

5. A brace according to any one of the preceding claims, characterized in that said closing means (8) which close the ends of the laces (52) are strips which have a bottom surface with hooks (20) and a top surface with loops (40) for Velcro-type coupling with said solid band (50) or with other closing strips (8).

6. A brace according to any one of the preceding claims, characterized in that said portions (5, 5') of the brace are obtained starting from a bonded multilayer sheet (1), by blanking.

7. A brace (100) according to claim 6, characterized in that said bonded multilayer sheet (1) comprises a bottom layer (2) destined to go towards the user's body, a middle layer of padding (3), and a top layer (4) destined to face outwards.

8. A brace (100) according to claim 7, characterized in that said bottom layer (2) is made of an anallergic, breathable fabric, said middle layer (3) is made of open-cell foam material, such as polyurethane (PU), and said top layer is made of a material like nylon, suitably treated to have a Velcro-type fixing surface (40).